Clad metal and method of making the same



Oct. 3,1939.4 T, B CHACE k 2,174,7

CLAD METAL AND METHOD oF MAKING THE SAME Filed Oct. 21. 1956 l BMD/N@ /F4C//Y6 METAL Patented Oct. 3.,l 1939 Ywarren STATES 2,174,733 CLAD METAL AND ME'rHoD or er` T HE SAME Th'omas'. iChace, Winnetka, Vlll., assignor, by direct and mesne assignments, to Clad Metals Industries, Inc., Chicago, Ill., a corporation of Illinois Application October 21, 1936, Serial-No.`106,86`9

8 Claims.

the cladding of one metal or alloy with another` metal or alloy of lower melting point, as will be apparent from the present specification.

In the cladding of steel, such as low carbon` lo steel, with a copper alloy such, for example, as

copper with a small percentage (0.5 to 5,0) of silicon, with or without other ingredients, such as manganese, tin, or the like in small percentage, it has been found difficult to s'ecure a direct bondwhi'ch Will be suflciently ductile to Withstand severe reduction in section such as is economical for rapid and inexpensive conversion to nish sheets, strip and the like.

In my prior application, `Serial No. 6,497, led

20 February 14, 1935, r have disclosed the ad.-

vantages of employing nickel as an ingredient of the bond for securing the desired qualities. The control of the nickel at the bond is diilicult if the nickel is to be confined to that region be- 25 cause nickel readily alloys, not only with the steel butalso with the copper. Also, since nickel by itself has a high melting point, it is dificult to handley in that manner.

` In my prior application, Serial No. 64,280, filed 3 February 17, 1936, I have disclosed the incorporation of the nickel in the copper silicon alloy whereby to gain a more definite control of the nickel and alsoI to facilitate and expedite the formation of the bond.

35 In the endeavor to secure a close` correspondence in physical properties between the copper alloy facing and the steel backing I have found it necessary to control the analysis of the /copper alloy v-ery closely, because the presence 40 of small amounts of alloying ingredients may cause pronounced changes in physical properties as Well as in corrosion resisting properties. I discovered, in keeping record of the analysis and corresponding properties, that the absorption of iron4 by the copper alloy was a factor which was not under definite control and hence undesired Variations of physical propertiesl and of cor` rosion resistance occurred.

Upon examining the various techniques Aemployed I noted that when silicon bronze was bonded directly to steel without abonding metal or alloy it is necessaryto leave the molten bronze in contact with the welding surface of the steel 55 for a period of froml 5 to 35 minutes. During this Soaking periodthe copper alloy tends, in some cases, to pick up a considerable amount of iron. For certain purposes the iron is objectionable. When nickel is embodied in the copper alloy, in addition to or as a substitute for silicon, and the copper alloy poured directly upon the face of the preheatedslab, a similar variation in the iron pickup may occur, due to variations in heating,`pouringor time during which the alloy is allowed to remain molten in contact with the iron.

The use ofv a layer of nickel confined to the region of the bond adds somewhat to the cost of practicing the process by introducing special handling and heating, but I observed that itcontains the possibility of segregating quite ef-v fectively the iron' and the copper siliconfacing, and I have,. according to the present invention, developed a simplified ,method of employing an intermediate or bonding layer which limits or g greatly reduces the escape of iron into the copper alloy. Thus I am able to maintain a close control of the analysis and hence physical and chemical properties of the facing metal.

Th'us, according to thel present invention, I apply to the welding face of the steel slab a layer kof metal or alloy, preferably an alloy of nickel such as a copper-nickel alloy or Monel metal or the like, which bonds readily to the steel backing with a tough, tenacious bond, and interposes a layer of a melting point sufficiently above that of the copper alloy employed for facing purposes that no serious migration of iron from vthe steel to the cooper facing can occur. The-transfer or migration of nickel from the bonding alloy to the facing alloy is not serious, as the addition of a small amount of nickel to the facing alloy does not objectionably alter the physical properties or corrosion resistance.

I have observed that where iron. migrates into the molten copper-silicon alloy/,it appears to float toward the surface of the said alloy. 'I'his is` probably due to the specific gravities involved, although I am not able to state this fromdenite knowledge. The high iron content near the surface maybe due to some other cause. vSuffice it Vto say, however, that the presence of iron at or near the` outer surface is generally undesirable.

By the present invention an effective barrier is interposed, and this barrier has the valuable quality of being itself not adversely affected by the absorption of iron,4 but provides a tough,

ductile bond capable of resisting the severe treatment of heavy rolling.

My invention further permits the use of inexpensive -scrap metal for the rather expensive junction with the size of the slab to which the same is to be applied, and likewise selection of these alloys shouldgbe made according to the carbon content of the'steel slab.

Another feature! of the present invention resides in the utilization of the bondingmetal as a source of nickel or similarly functioning in.-

gredient` for the facing metal.

Where the thickness of facing metal is to be reduced to a minimum as for example 5% to 10% instead of 10% to 20% ofthe thickness of the g finished sheet, bar, rod or the like it is particularly important to minimize the migration of iron into the facing metal; at the same time it is desirable that the bonding layer be held at minimum thickness in order to give maximum thickness of the facing metal within the limits selected. Thus by employing a bonding metal high in nickel a bond which limits migration of iron may be secured and this in turn may, when the facing metal is poured upon the same, serve as a source of `nickel for reenforcing the physical or other properties of the facing metal.

It is desirable thave nickel in combination with silicon for other purposes than bonding or for p'urposes in addition to bonding. Silicon copper comprising 156% silicon or less is not sufficiently refractory to roll evenly with .12% carbon steel whereas 1%% of Asilicon and 11,4% of nickel alloyed with copper form silicides in the copper which make the alloy more refractory. It is to be understood that small percentages of other ingredients such as manganese tin or the like may be added to improve the workability of the copper base alloy when that is desired without departing from the teachings of my invention.

Now in order to acquaint those skilled in the art with the manner of practicing my invention I shall describe, in conjunction with,y the accompanying drawing, a specific embodiment of my invention.

In the drawing:

Figure 1 is a vertical section through the open-faced mould when the same is charged with bonding metal and flux preparatory to heating of the'slab;

Figure 2 is a similar section showing the bonding metal melted and bonded to the steel backing, with the flux floated to the top of the bonding metal, as occurs during lpreheating of the slab;

Figure 3 is a similar sectional view of the openfaced mould, with the facing metal poured on top of the` bonding metal'and the ux being floated of! the surface of the facing metal;

Figure 4 is ai similar sectional view of an open-faced mould with the bonding metal poured from a ladle or the like onto the surface of the slab, displacing the iiuxv which 4covers the welding face of the slab:

Figure 5 is a fragmentary vertical 'section through a clad slab illustrating the relation of the facing metal, the bonding metal, and the steel backing: and

Figure 6 is a vertical fragmentary section through a double clad slab with the facing metal of the two slabs towards each other for the purpose of rolling a double slab.

I have found that silicon-copper alloys are dimcult to bond directly to steel, and require comparatively long soaking time to create a bond which can be subjected to rolling and other working operations; The long soaking period permits excessive iron pickup from the steel base and changes the analysis of the silicon-copper alloy. By first, bonding a thin layer of pure copper, or a copper alloy low in silicon, the soaking period can hej reduced. A good weld is made at the'flrst urrion-L and a second'layer, of a higherl silicon copper, will? bond quickly at the second union,requiring only-normal cooling to the freez- Aing point, which minimizes iron .migration to the outersurface. The melting temperatures of the ilrst and lsecond layers of copper alloys are approximately the same, and in producing very large slabs the temperature is maintained long enough by the large mass to remelt the first layer, even though allowed to cool well below the melting temperature before the second layer is poured.

The specific gravity of iron is 7.9, compared to copper: 8.851 sor distribution through the copper alloy is'. relatively rapid. By utilizing an alloy free of iron and having all the other properties required; includinga melting temperature between the steel base and the main copper alloy facing, very good control of iron migration is accomplished. A 50% nickel and 50% copper -alloy melts at about 2400 F. 'Ihis alloy bonds quickly to lsteel by melting on the steel base during preheating and requires only the normal cooling in air from the molten state for the soaklng period. This might absorb from 1% to 2% of iron during soaking, but as only a thin layer is required, about 3'; inch in depth, the subsequent thick layer of the high copperalloy or silicon copper which makes up' the main facing is kept substantially free from iron. Silicon copper, or a high copper alloy having a melting temperature below -the bonding material will weld quickly to the bonding material, requiring only normal cooling inv air after being applied in the molten state. Since the main facing alloy is separated fromthesteel base so that there is no contact of the two outer metals, the iron pickup therein is from the small amount in the bonding material which, when distributed through the thickness of several inches, is a `negligible amount and is relatively unimportant.

ture copper-nickel alloy of 70% copper and 30% nickel, having a melting temperature of around 2240 F. This choice would depend somewhat on 4the size of the slab, on ythe details of equipment available for carrying out the process, and other factors.

Nickel-copper alloys are very sensitive to atmosphere and must be kept completely sealed from furnace gases.

The bonding alloy can be first welded to the steel base from any number of forms. After the steel base which makes up the bottom of they open-faced mould has been cleaned and-iluxed with a covering of boric acid powder or the like, the correct weight of bonding alloy can be added as a thin sheet, powder, stock, or scrap metal,

. and completely covered with additional boric acid powder so as to seal the bonding metal as well as the welding surface of the steel from atmosphere, as illustrated in Figure 1. as shown in- 75' borax, glass, or other suitable flux-which meltsv at a temperature lower than the oxidizing temperature of the nickel-containing bonding material 4. As the bonding metal fills only a small depth of the mould it can easily be kept covered with flux both prior to Aand during the melting of the said bonding metal 4. The assembly shown in Figure 1 is subjected to furnacetemperature high enough to melt the bonding metal 4 (slightly above 2400 F. for a 50% copper and 50% nickel alloy). The bonding metal is applied in solid form, as shown in Figurel, melts, and runs out evenly over the steel surface under the flux, assuring contact and uniformly perfect bonding throughout the entire surface 3. The.

-ux 5'floats to the top, completely sealing the bonding metal. The bonding metal, when'cooled to room temperature 'andhaving the flux broken `away from the same, shows a clear, bright, shining surface for welding of Athe high copper alloy thereto.'

After the melting of the bonding metal and the bonding of the same to the surface 3, .the assembly shown in Figure `2- is then removed to a level table outside of the furnace and allowed to cool to a temperature under the freezing temperaturef the bonding metal 4, or approximately 2100o F. Thereupon, the remainder of the mould is lled with molten silicon-copper 6.' as from the. ladle or crucible 1, -or it may be filled with alower melting point high copper alloy. 'This facing metal 6 bonds very readily and quickly tothe copper-nickel surface of the layer 4 and is kept in molten co-ndition only long enough for ythe fiuxeand other non-metallic particles to work to the surface, as indicated at 5. When siliconcopper is employed for the facing layer 6 the ux and slag can be skimmed` oil immediately after pouring and while still molten". -as silicon copper can be exposed to air when molten and it freezes with only a thin oxide on the surface. which is quite satisfactory for rolling without cleaning or machining operations. The flux and slag 5 may 'be skimmed off by running a at. long-handled,

snade-shaped instrument across the ton. this in` strument resting von the upper edge of the`two side strips. AThe mould is poured full to the tou nf thedstrips 2 with the facing metal. particularly where copper-silicon alloy is employed. so that the fused ux stands above the rim ofthe mold str-io 2 and skims oif very easily. Then, as soon as the facing metal on the slab solid'es. the

. composite slab may be rolled at a hot rolling temperature.

The steel slab I, with the open mould formed thereupon by the peripheral strip 2, may, as shown in` Figure 4, be fluxed and preheated and the bonding metal melted independently as in the crucible or ladle 8, and poured onto the surface 3 of the steel slab to the proper thickness; The molten bonding metal will flow under the flux,

as shown in Figure 4, and distribute itself overv the surface 3, and when the assembly is cooled to below the freezing temperature of the bonding metal the high copper'facing alloy can be poured to filll the mould. I

There is some nickel pickup from the bonding metal 4, but this, of course, does not aifectthe corrosion-resisting properties of the high copper alloy and in some cases, such as a 11/% siliconcopper alloy, an addition of nickel is desired Vfor improving the rolling properties. Nickel does not migrate into copper as readily as iron. as the,

specific gravity of nickel is 8.8 compared to iron 7.9 and copper 8.85.

I have made analyses `x,of samples taken from various regions of the facing .alloy andy of the bonding alloy. In the case of a composite slab of the dimensions shown in Figure 5, using a copper-nickel bonding metal'r of 50% copper and 50% nickel, and using a. facing metal of silicon bronze employing substantially 11/2% silicon, I

nd that the outer surface portion I of the facing metal 6 exhibits an .analysis of'-.

' y Percent Copper 95.89 Silicon 1.22 Nickel 1.24 Iron 1.28

For the region represented by the metal within 1A; inch above the bonding alloy 4, the analysis showed the following: n

Percent Copper 94.92 Silicon .97 Nickel 2=69 Iron .'95

The analysis ef the bending menu 4, as'mdicated at l2, showed the following:

Percent Copper 44.99 Nickel 45.95 Iron 7.15

The slab in Fig. represents a ten minute soaking .of the copper-nickel bonding alloy in the molten state on the steel and a thirty minute soaking of the silicon copper facing metal in molten state on the copper nickel bonding alloy.

A similar slab processed with a thirty minute soaking of the'silicon facing metal in molten state on the steel showed 5.67% iron at the outer surface portion I0.

A similar slab processed without soaking the copper-nickel bonding alloy but with a thirty minute soaking -of lthe silicon copper facing metal showed in analyzing of the outer portion I0, only .36 iron and 1.29 nickel.

Asimilar slab processed without soaking either `copper-nickel.bonding'alloy or the silicon copper facing alloy, which was -done by pouring the bonding alloy and allowing it to solidify and then pouring the facing alloy and allowing it to solidify, showed only a .09 iron at portion I0.

A similar slal processed without the use of the bonding alloy and without soaking the silicon copper facing metal but .by merely pouring the facing'metal on the steeland allowing it to solidify showed in the analysis .96 .iron at portion I0.

This last example did not produce avbond between the facing metal and the steel and the slab consequently separated in rolling. To create a vbond suitable for rolling between silicon copper and steel, it is necessary to soak the silicon copper in molten state for a period'which varies with the silicon content. The use of the nickelbonding alloy eliminates the necessity of the soaking period as the combinations bond readily to each other if merely poured in the molten state y nickel which can be done by prolonging the soaking of the low silicon copper facing metal until sumcient nickel has migrated into the copper and the iron pick-up still maintained at the ininimum. f

. Thus, by control of the soaking time, i. e., the

time during which'the facing metal is held in f solidify the facing metal occupies some consid-` molten condition upon the face of the solid but heated bonding metal the pick-up of lnickel from the bonding metal may beregulated to give the desired composition of the facing metal. 'Ihis teaching is of value in regulating the composition of the facing metal particularly in the case .of large slabs for the reason that with a large mass the cooling down of the mass -to freeze or erable time. By taking into account the nickel pick-up which will thus occur-it is possible to get the. right composition by starting with a facing alloy lacking the amount of nickel which the period of cooling will pick up. A certain amount of silicon may migrate withthe bonding layer. This is not objectionable. Infact, I may add a small amount (i. e., up to 195%) of silicon to said bonding alloy.

Composite slabs produced as above described may be rolled in four-ply assemblies, as shown in Figure 6, the cuprous facings 6 and 0' being' put face-to-face, with a separating compound I3 between them', and the mould strips 2 and 2' welded together by a fusion weld il, asindicated in Figure 6. Thereby the copper alloy is protecied from atmospheric influence during rolling, the arc weld at y holding the two composite slabs together. The. faces 'of the silicon-bronze layers need fonlybe cleaned oil! as `by sand blasting prior to assembly as shown inFigure 6. If the slag and iiux are otherwise removed, sand blasting is not necessary. Since thearc weld Il may be made about he entire periphery of the double thickness sab, the exclusion of atmosphere is entirely satisfactory.

I do not intend to be limited-to shown and described.

I claim:

i. A clad metal comprising a backing of metal rich in iron, afacing of copper silicon lalloy and the details a bonding layer ofnickel alloy between the backing and facing of suchthickness as to substantially prevent migration of iron into the facing when the latteris boncled to the bonding layer.

2. The method of facing a steel backing with y a corrosion resisting metal .substantially free of iron, which comprises bonding to the face of the steel backing a thin intermediate layer of a nickel-'copperalloy of such thickness as to substantially prevent migration of iron into the corrosion resisting metal from the steel backing arr-aras when the corrosion resisting metal is bonded to the intermediate layer and then bonding to the face of the layer of nickelcopper alloy a facing of copper-silicon alloy. 4

3. The method of claim 2 wherein the intermediate layer is bonded to the steel backing while molten andthen allowed to solidify and the facing layer is bonded in molten condition to the solidied face of the intermediate layer.4

4. The method of making copper clad steelf which comprises first bonding to a face of the steel a thin'layer of a nickel-copperalloy of av v mediate layer of bonding alloy rich in nickel,

fusion welded to the steel base and of such thick# ness as to substantially (prevent migration of iron into the alloy facingfwhen the latter is weldedl to the-intermediate layer, and having the facing alloy fusion kwelded to the bonding layer.

6. The method of cladding steel with-a cuprous facing having strength and rolling qualities com.

parable to Steef which comprises cleaningthe face `of the steel, covering the same with flux, depositing in molten form upon the face Vof the steel a layer of copper-nickel alloy containing from to 70% of nickel and of such thickness `as to substantially prevent migration of iron from the lsteel to the cnprous facing when the vlatter isbonded to the layer of`coppernickel alloy, allowing said layer to solidify, depositing upon said layer af facing layer of copper containing approximately 11/2% silicon and holding said facing layer in molten condition long enough to pick up from the ilrst layer nickel to the amount'of approximately 1Vg% and then allowlng the facing layer to solidify.

7. A clad metal comprising a low carbon steel 'backing, a facing of copper alloy containing less than 5% silicon, and a bonding layer of nickelcopper alloy containing nickel ranging from 20% to 80% between the backing and facing of such thickness as`to substantially prevent migration of iron into the facing when the latter is bonded to the bonding layer.

8. A clad metal comprising a backing of metal high in iron, afacing layer of copper-silicon alloyrsubstantially free of iron, and a thin intermediate bonding layer comprising chiefly nickel bonded to tlie backing, the facing layer having a lower melting point than the intermediate layer and beingfusion bonded tol thexintermediate layer. g

THOMAS CHACE. 

